Heat resistant, stain resistant, and anti-bacterial fabric and method of making same

ABSTRACT

A high performance fabric comprised of a plurality of high-performance fibers coated with an anti-microbial compound and an anti-stain compound, where the high-performance fibers are polyester microfibers for comfort. The anti-microbial compound is a wash resistant non-organic antibacterial or a non-organic microbicidal. The anti-stain compound is hydrophobic or superhydrophobic, preferably polytetrafluoroethylene or silicone. Optionally, additional flame resistant fibers are interwoven with the high-performance fibers to increase flame resistance.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 14/971,780, filed on 2015 Dec. 28, the contents of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to fabric and more specifically to a heat resistant, stain resistant, and anti-bacterial fabric.

BACKGROUND

Currently, there are a variety of individual fabrics that are stain resistant or anti-bacterial or heat resistant. However, there isn't a single fabric that performs all three functions. For example, the military uses fire retardant clothing to protect personnel. However, the heat resistance of the fabric works both ways so that heat is also trapped inside the garment, causing an uncomfortable rise in body temperature and unwanted bacterial growth. Fire departments routinely use similar material with the same result. New fabrics, such as, for example, Coolmax®, Coolplus®, and Bodycare Moisture® have been developed to reduce body temperature by wicking moisture away, but are mainly used in the sporting garment industry to keep the wearer cool. Some fireproof garments contain an inner lining of wicking material, but this adds to bulk to the garment, and the moisture can still be trapped inside the heat resistant layer eventually defeating the purpose of the fabric. In the food industry, it would be very useful to have a garment that is stain resistant rather than the traditional cotton chef's coats and aprons that are used today. In all of these industries, and in home use, it would be beneficial to have a fabric that comprises the best qualities of each individual fabric without the extra cost involved in using multiple fabrics and without adding bulk to the garment.

Therefore, there is a need for a heat resistant, stain resistant, and anti-bacterial fabric that does not have the problems in the current art.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying figures where:

FIG. 1 is a flowchart diagram of some steps of a method for making a heat resistant, stain resistant, and anti-bacterial fabric, according to one embodiment;

FIG. 2 is an outside portion a new style chef's coat made with the fabric;

FIG. 3 is an inside portion of a new style chef's coat made with the fabric; and

FIG. 4 is another outside portion of a new style chef's coat made with the fabric.

SUMMARY

A high performance fabric made from a plurality of high-performance fibers with an anti-microbial compound and an anti-stain compound. The high-performance fibers are polyester, where the high-performance polyester fibers are polyester microfibers for comfort. The anti-microbial compound is a wash resistant non-organic antibacterial or the anti-microbial compound is a non-organic microbicidal. The anti-stain compound is a hydrophobic compound, a superhydrophobic compound or both a hydrophobic compound and a superhydrophobic compound. Alternatively, the anti-stain compound is polytetrafluoroethylene, silicone or both polytetrafluoroethylene and silicone. Preferably, the anti-stain compound is polytetrafluoroethylene. Additionally, the fabric has additional flame resistant fibers interwoven with the high-performance fibers to increase flame resistance, where the flame resistant fibers are aramid fibers. The fabric has between 10% and 50% of additional flame resistant fibers. Preferably the fabric comprises 50% of additional flame resistant fibers.

A method making a high performance fabric by first creating a flame resistant fabric blend comprising inherently flame resistant fibers. Then, coating the flame resistant fabric blend with an anti-microbial compound. Finally, coating the flame resistant fabric blend with an anti-stain compound affixed to the high-performance fibers. The flame resistant fabric blend is made of polyester microfibers, where the flame resistant fabric blend is comprises polyester microfibers and aramid fibers. The fabric is drawn through a water-based dispersion to coat the fabric with the polytetrafluoroethylene, where the water is heated to a temperature approximately between 70° C. and 100° C. Alternatively, the fabric is drawn through a silicone-based dispersion to coat the fabric with silicone, where the silicone-based dispersion solution is heated to a temperature of approximately 70° C. and 100° C. The fabric is then spray coated with a hydrophobic or superhydrophobic compound.

DETAILED DESCRIPTION

The present invention overcomes the limitations of the prior art by providing a heat resistant, stain resistant, and anti-bacterial fabric.

All dimensions specified in this disclosure are by way of example only and are not intended to be limiting. Further, the proportions shown in these Figures are not necessarily to scale. As will be understood by those with skill in the art with reference to this disclosure, the actual dimensions and proportions of any system, any device or part of a system or device disclosed in this disclosure will be determined by its intended use.

Methods and devices that implement the embodiments of the various features of the invention will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention. Reference in the specification to “one embodiment” or “an embodiment” is intended to indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least an embodiment of the invention. The appearances of the phrase “in one embodiment” or “an embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

Throughout the drawings, reference numbers are re-used to indicate correspondence between referenced elements. In addition, the first digit of each reference number indicates the figure where the element first appears.

As used in this disclosure, except where the context requires otherwise, the term “comprise” and variations of the term, such as “comprising”, “comprises” and “comprised” are not intended to exclude other additives, components, integers or steps.

In the following description, specific details are given to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific detail. Well-known circuits, structures and techniques may not be shown in detail in order not to obscure the embodiments. For example, circuits may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail.

Also, it is noted that the embodiments may be described as a process that is depicted as a flowchart, a flow diagram, a structure diagram, or a block diagram. The flowcharts and block diagrams in the figures can illustrate the architecture, functionality, and operation of possible implementations of systems, methods, products and devices according to various embodiments disclosed. It should also be noted that, in some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be rearranged. A process is terminated when all its operations are completed. A process may correspond to a method, a function, a procedure, etc.

In the following description, certain terminology is used to describe certain features of one or more embodiments of the invention.

The term “flame resistant” refers to a treatment or a natural property that provides self-extinguishing capabilities when exposed to an ignition source.

Various embodiments provide a heat resistant, stain resistant, and anti-bacterial fabric. One embodiment of the present invention provides a method for making a heat resistant, stain resistant, and anti-bacterial fabric. In another embodiment, there is provided a product for using the fabric. The system and method will now be disclosed in detail.

Referring now to FIG. 1, there is shown a flowchart diagram 100 of some steps of a method for making a heat resistant, stain resistant, and anti-bacterial fabric, according to one embodiment. First, a high performance fabric is created. The fabric is a flame resistant fabric blend comprising inherently flame resistant fibers 102, such as, for example polyester. Then, the flame resistant fabric blend is coated with an anti-microbial/bactirial compound 104. Next, the flame resistant fabric blend is coated with an anti-stain compound. The polyester in the flame resistant fabric blend is preferably comprised of polyester microfibers for comfort and durability. Optionally, the flame resistant fabric blend can comprise a combination of polyester microfibers and aramid fibers interwoven with each other. Although polyester is a naturally flame resistant material, the addition of aramid fibers can add additional flame resistance, durability and stain protection. The amount of aramid fibers should not exceed 50% of the total fabric weight so that the more rigid aramid fibers will not reduce the flexibility of the overall fabric or add additional bulk to finished garments made from the fabric.

To coat the high performance fabric with an anti-stain compound 106, the fabric is drawn through a water-based dispersion with the polytetrafluoroethylene. To permeate the fabric, the water is heated to a temperature approximately between 70° C. and 100° C. This will loosen the fiber so that the polytetrafluoroethylene can fully impregnate the fabric. Alternatively, the fabric can be drawn through a silicone-based dispersion to coat the fabric with silicone. In this case, the silicone-based dispersion solution is heated to a temperature of approximately 70° C. and 100° C. to loosen the fibers and allow for deep penetration. Preferably, the fabric is coated with polytetrafluoroethylene as it is more durable through repeated washings than the silicone. Additionally, the polytetrafluoroethylene adds a brightness and sheen to the fabric that is desirable for use in the finished garments. Also, the fabric can be sprayed with a hydrophobic or superhydrophobic compound in addition to the polytetrafluoroethylene or silicone treatment. This would add an extra layer of stain protection to the fabric. However, current hydrophobic and superhydrophobic compounds are not as resistant to repeated washing and would need to be re-applied periodically, typically after every 10 washes.

Referring now to FIG. 2, there is shown an outside portion 200 a new style chef's coat 202 made with the fabric disclosed above. In this case, a new style of chef's coat 202 has been made with the fabric. Currently, chef's coats are made from cotton and other cellulous materials that stain easily and require heavy duty cleaning compounds to remove stains that are typically encountered on a daily basis. Some currently available chef's coats use polyester, however, they do not have the additional properties of the disclosed fabric. As noted above, polyester is inherently flame retardant, and therefore doesn't flare up when applied to various levels of flame or heat. Any amount of heat delivered within a long enough time interval will have no impact on the fabrics' integrity while a limited amount of heat delivered within short enough time interval may ignite or melt the fabric. However, polyester by itself also traps heat within the garment making it uncomfortable to wear for extended periods of time. The disclosed fabric uses a breathable microfiber polyester that retains the original properties of the material while adding additional comfort by wicking away moisture from the wearer. The treated fabric will also maintain the garments good looks throughout a shift making the cooking staff look professional at all times. The stain repellent nature of the treated fabric will prevent messes due to cooking. The antimicrobial coating of the fabric will reduce the change of food contamination from outside sources and eliminate body odor and other bacterial sources from inside the garment. As can be seen, the new style chef's coat also comprises power mesh inserts 204 under the arms for additional garment breathability.

Referring now to FIG. 3, there is shown an inside view 300 of a new style chef's coat 202 made with the fabric. The inner portion 302 of the new style chef's coat is made from the same or similar fabric to the outside 200. Similar fabric can have a greater amount of microfibers so that the inner portion 302 is more comfortable to wear or it can provide better moisture wicking or heat resistance as needed for the job. Alternatively, the outer portion 200

Referring now to FIG. 4, there is shown another outside portion 400 of a new style chef's coat made with the fabric. As can be seen, this outside portion 400 is more tailored and suitable to a female chef. Additionally, a micromesh insert 402 runs the length of the sleeve, not just the underarms 204. This can be used in very hot kitchens or just as a stylish addition to the kitchen.

As will be understood by those with skill in the art, many variation of garments can be made from the disclosed fabric other than a chef's coat and the above exemplars and not intended to be limiting. There are a great many other industrial, commercial, service and home uses for a fabric comprising all the properties disclosed herein.

What has been described is a new and improved system and method for a new and improved heat resistant, stain resistant, and anti-bacterial fabric, overcoming the limitations and disadvantages inherent in the related art.

Although the present invention has been described with a degree of particularity, it is understood that the present disclosure has been made by way of example and that other versions are possible. As various changes could be made in the above description without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be illustrative and not used in a limiting sense. The spirit and scope of the appended claims should not be limited to the description of the preferred versions contained in this disclosure.

All features disclosed in the specification, including the claims, abstracts, and drawings, and all the steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

Any element in a claim that does not explicitly state “means” for performing a specified function or “step” for performing a specified function should not be interpreted as a “means” or “step” clause as specified in 35 U.S.C. § 112. 

What is claimed is:
 1. A high performance fabric, comprising: a) a plurality of high-performance fibers; b) an anti-microbial compound affixed to the high-performance fibers; and c) an anti-stain compound affixed to the high-performance fibers.
 2. The fabric of claim 1, where the high-performance fibers are polyester;
 3. The fabric of claim 2, where the high-performance polyester fibers are polyester microfibers for comfort.
 4. The fabric of claim 1, where the anti-microbial compound is a wash resistant non-organic antibacterial.
 5. The fabric of claim 1, where the anti-microbial compound is a non-organic microbicidal.
 6. The fabric of claim 1, where the anti-stain compound is a hydrophobic compound, a superhydrophobic compound or both a hydrophobic compound and a superhydrophobic compound.
 7. The fabric of claim 1, where the anti-stain compound is polytetrafluoroethylene, silicone or both polytetrafluoroethylene and silicone.
 8. The fabric of claim 7, where the anti-stain compound is polytetrafluoroethylene.
 9. The fabric of claim 1 further comprising additional flame resistant fibers interwoven with the high-performance fibers to increase flame resistance.
 10. The fabric of claim 9, wherein the flame resistant fibers are aramid fibers.
 11. The fabric of claim 9, wherein the fabric comprises between 10% and 50% of additional flame resistant fibers.
 12. The fabric of claim 11, wherein the fabric comprises 50% of additional flame resistant fibers.
 13. A method making a high performance fabric, the method comprising the steps of: a) creating a flame resistant fabric blend comprising inherently flame resistant fibers; b) coating the flame resistant fabric blend with an anti-microbial compound; and c) coating the flame resistant fabric blend with an anti-stain compound affixed to the high-performance fibers.
 14. The method of claim 13, where the flame resistant fabric blend comprises polyester microfibers.
 15. The method of claim 13, where the flame resistant fabric blend is comprises polyester microfibers and aramid fibers.
 16. The method of claim 13, where the fabric is drawn through a water-based dispersion to coat the fabric with the polytetrafluoroethylene, where the water is heated to a temperature approximately between 70° C. and 100° C.
 17. The method of claim 13, where the fabric is drawn through a silicone-based dispersion to coat the fabric with silicone, where the silicone-based dispersion solution is heated to a temperature of approximately 70° C. and 100° C.
 18. The method of claim 13, where the fabric is spray coated with a hydrophobic or superhydrophobic compound. 